Method of forming cylinder lock housing of strip material



April 18, 1961 F. J. RUSSELL 2,979,812

METHOD OF FORMING CYLINDER LOCK HOUSING OF STRIP MATERIAL Filed June 23, 1958 Patented Apr. 18, 1961 IWETHOD OF FORMING CYLINDER LOCK HOUSING OF STRIP MATERIAL Fred J. Russell, 3800 Don Felipe Drive, Los Angeles, Calif.

Filed June 23, 1958, Ser. No. 743,686

'5 Claims. (Cl. 29463) The invention relates to lock housings and particularly lock housings for a type of lock commonly designated a cylinder type lock. More particularly the patent has reference to a method of forming such a cylinder lock housing of strip material instead of forming it by machining the device from east or extruded stock.

One of the elements of door lock hardware which has for a long time presented certain problems to the designer and manufacturer has been the lock housing for cylinder type locks in which there is customarily provided a series of spaced cylindrical bores designed to receive pin tumblers and their springs and to retain them in proper actuating position. Although reliable and effective cylinder lock housings have been in substantially widespread use, they have been somewhat costly to manufacture because of the established practice of machining them from solid brass stock. The machining operation is not only costly from the point of view of raw material, but is wasteful in that a substantial amount of scrap must necessarily result and further because an unnecessarily large number of manufacturing operations have been needed. Further still, because of the peculiar design of these parts and the necessity for accurately aligning the pin tumbler bore, the manner of forming those bores has been such that some apertures necessarily made in the manufacturing process have necessitated the making of additional apertures not useful in the finished product and which necessitate a still additional operation to seal them or plug them and refinish the surface before the device is acceptable as an operating structure.

It is therefore among the objects of the invention to provide a new and improved cylinder lock housing and method of forming the same which makes possible the fabrication of the parts from strip material as a consequenced of a relatively few, simple manufacturing operations.

Another object of the invention is to provide a new and improved method of forming cylinder lock housings which makes use of a certain few stamping and folding operations, thereby constituting a very simple manufacturing process which, however, results in a rugged and dependable type of device.

Still another object of the invention is to provide a new and improved method for the forming of a cylinder lock housing which entirely eliminates machining operations and substitutes therefor die operations on relatively fiat stock accompanied by a subsequent simple folding operation in certain forms of the invention.

Still further among the objects of the invention is .to provide a new and improved method of forming cylinder lock housings by means of which complementary halves of a cylinder lock housing can be formed by a stamping or pressing operation and the halves thereafter positioned face to face and connected together by bending portions of the material, thereby making possible the fabrication of a dependable lock casing by simple and inexpensive means.

A still further object of the invention is to provide a new and improved cylinder lock housing of thin gage sheet material with portions molded for reception of operating parts and exterior elements thereon interlocked to provide a rugged durable device.

With these and other objects'in view, the invention consists in the method for achieving the construction, arrangement and combination of the various parts of the device whereby the objects contemplated are attained as hereinafter set forth, pointed out in the appended claims and illustrated in the accompanying drawings.

In the drawings:

Figure 1 is a perspective view of a piece of metal strip from which the device is formed.

Figure 2 is a perspective view showing the piece after completion of the first phase of its forming.

Figure 3 is an end elevational view showing the second phase of its forming.

Figure 4 is an end elevational view of the device after final forming.

Figure 5 is a cross-sectional view taken on the line 55 of Figure 4.

Figure 6 is a perspective view of a two-piece device after completion of the first phase of its forming.

Figure 7 is an end elevational View of the two-piece device after the final forming.

In the exercise of one form of the method productive of the device illustrated in Figures 1 through 5 there is provided a piece of strip material of substantially uniform thickness which, if preferred, may be cut from a length of strip material of appropriate size and thickness. The simple piece of strip material is indicated by the reference character 10. It will be noted that by reason of making use of a strip of the material of adequate size, the pieces 10 may be stamped out, leaving desired tabs of metal at appropriate locations during a cutting process. It should be understood that the cutting may, if desired, be included as part of the novel stamping process.

An acceptable means of employing the method is to have prepared a pair of respective male and female dies, the female die having the shape and configuration of an underside 11 of a part resulting from the first phase of the method and the male die having a form conforming to an upper face 12 of the part.

It should further be appreciated that the female die (not shown) can be simple in that it may comprise recesses adapted to receive and form the under face of the piece as the male die (not shown) having complementary projections is forced into position to form the upper face 12.

By press operations all of the configurations on both upper and lower sides of the piece may be formed simultaneously. The depressions made mention of comprise a wide deep recess indicated generally by the reference character 13 and which may be said to comprise complementary impressions 14 and 15 on respectively opposite sides of a longitudinal center line 16. Generally speaking the recess 13 will be relatively fiat along the longitudinal center line at this step in the process but will have a sufficient transverse length so that it will form a cylindrical hole of proper size following the ultimate step of the method.

The portions of the strip which become the parts forming the impressions 14 and 15 may appropriately be defined as inner sections of the strip or, in other words, sections closest to the longitudinal center or dividing line.

Similarly adjacent the portion forming the impression 15 is a part of the initially selected piece which may appropriately be defined as an outer section 17- While on the other sideis another piece which may be appropriately defined as an outer section 18.

These outer sections in each instance have impressed into their innerfacesaseriesof spaced semi-cylindrical depressions. Those depressions made in the outer section 17 are identifiedrwithfthe reference character 19. Those depressions made in the outer section 18 have been given the Ieferencechar'acter'Zt}. It is preferable thatrthese depressions be s'ubstantially semi-cylindrical in form and that the depressions *19 match and be coml'ple'rnentary' to the" depressions 2t Strips 21 act as spacer-[s between adjacen'tjdepressions. At the outer ends 'of the depressions .19 are endlwalls 119' and end .walls close totheouter ends of the depressions' Ztl.

In orderto fas'tenth'e formed piece in assembled condition, endtabs 22-and 23 may be formed on end faces 24 and 25,'respectively. Similarly tabs 26 and 27 may be formed respectively on end faces-28 and 29. Adjacent the e'ndwalls 19' on the outer'section 17 is a flat strip 30 from which extend tabs 31 and 32. Similarly on the outer section 18 is a flat strip 33 from which extend tabs .34 and SSJtaggeIed with respect to the tabs 31 and 32.

After the strip has been given the form illustrated in Figure 2 which may be accomplished by a punch press machine where appropriate female and male dies are made u'se o'f, the initially formed part is ready to be folded into final shape. This may be accomplished effectively b'y employment of a mandrel 36 which has the proper diameter in order to result in the formation of a hole of proper dimension for reception of a conventional cylinderplug used in the type of cylinder lock here made reference to. v

The mandrel 36 is placed in the recess13 where it may be forcibly held by appropriate conventional means notrimportantlto the steps. herein particularly described. With the mandrel inplace theouter sections 17 and 18 are pulled over the exposed face of the'mandrel toward each other until the stripsj21 are pressed face to face, as illustrated in Figure 3. This step in the method includes carefully aligning the semi-cylindrical depressions with each other so that when the outer sections are pressed together, the complementary depressions will complete the formationof a series of spaced parallel pin tumbler bores. By use of appropriate .and wellknown folding apparatus, the opposite sections 17 and 18 may v beheld in proper p osition, at which time the impressions 14 and 15 arelikewise turned properly over the cyhndrical circumference ofthe mandrel .36. While being firmly held in the last described position, the tabs 22, 23,26 and 27 maybe bent around the sides as shown in Figure 4 and thereforced into engagement by pressure in order to firmly anchor the parts in assembled condition.

During the same phase of'the' process, tabs 31 and 32 are folded between tabs 34=and 35 and aroundthe outer face of the flat strip 3 3- Similarly the tabs 34 and 35 are folded between theytabs 31 and 32 and pressed against the outer face' of the flat strip'30.

Where the first method step is effectively performed a and the impressionsmadewith' a 'sufiicient degree of fidelity, thepin tumbler bores will not need further sizing or machining and the employment of the'mandrel 36 will assure that the finally formed. cylindrical recess 13 will be true and correct'. andproperly receptive of the cylinder lock when that part is ultimately assembled withit, The method heretofore described;contemplates forming the entire cylinder lock housing from a single piece .of strip material. derived from employing two separate pieces of material about half the breadth of thepiece 10. When this modified form of the method is practiced, there will be struck complementary half sections 49 and 41, illustrated in Figure 6. Thehalf sections may be made complernentary in all respects to the extent that there is formed in the half section 40 a semi-cylindrical recess 42 and in the half section 41 a semi-cylindrical recess 43.

At the same time as the, semi-cylindrical recesses 42 and 43 are formed, there are also formed -in the half section 40 a series of spaced parallel semi-cylindrical depressions 44 having end walls 45. Similarly in the half section 41 there will be formed a corresponding set of complementary spaced semi-cylindrical depressions 46 having end walls 47. Also during the forming of the half section 40, tabs 48 and 49 may be formed on opposite ends 59 and 51 respectively. Tabs 52 and 53 are formed in substantially the same fashion on ends 54 and 55 of the half section '41, the tabs at opposite ends being staggered with respect to each other. A flat strip having tabs 61 and 62 is formed on the half section 49 and a fiat strip 63 having tabs 64 and 65 is formed on the half section 41. Tabs on opposite sides in this instance also are staggered with respect to each other. 7 A

To interlock the half sections together at the area of the recess 42 and 43-there are provided apertures and 67 in the halfsection '40 in alignment with tabs 68 and 69 in the half section 41. Tabs 70 and 71 in half section 40 are formed in alignment with apertures 72 and 73 in the half section 41. As shown, the staggered half sections 40 and 41 are matched and placed in position face to face after the tabs 68, 69, 70 and 71 are inserted through their respective apertures 66, 67, 72 and 73. The half sections are then pressed together so that strips 74 of the half section 40 are pressed face to face into engagement with strips 75 'of the half section 41.

Whileheld'firmly inplace the tabs 48, 49, 52 and 53 are bent around the opposite sides, as shown in Figure 7. Tabs 61 and 62 are bent around the outer face of the flat strip 63 and tabs 64 and 65 are bent around i the outer face of the flat strip 60. Tabs 61 and 62 may 'be bent against the opposite half section and tabs 64 and 65' may be bent outwardly, as shown in Figure 7,

' to assure a firm interlock. Tabs 68, 69, 70 and 71 may be bent 'as shown in Figure 7, care being exercised to preserve the contours of surfaces 42 and 43. In this form employment of a mandrel like the mandrel 36 may be dispensed with.

It will be understood'and appreciated from the foregoing described method with respect to both forms thereof that the operations of forming cylinder-lock housings heretofore in vogue have been very greatly simplified 55 by the method defined and disclosed. Moreover, by use ofv the method inthe manner described it is possible to make use of stock material ,of a much less expensive type in order to ultimately form the cylinder lock housing. By use of the method and technique of the disclosed invention, moreover, a substantial degree of precision is assured with respect toforming both the recess for V the .lock cylinder and the bores for the pin tumblers. The

employment of the rnethodtherefore results in production I of parts for locks which are materially less costly, result- Some advantages,-however,may be P ing in an appropriate benefit to all types of users.

While I have herein. shown and described my invention in what; I have conceived to be the most practical and preferred embodiment, it is recognized that departures may be made therefrom with the scope of my invention, which is not to be limited to the details disclosed herein but is to be accorded the full scope of the claims so as to embrace any and all equivalent methods.

7 Havingjdescribed my invention, what I claim as new and desire to secure by'Letters Patent is:

' '1. A method offornring'a cylinder lock housing having a cylinder plug recess and pin tumtler bores in communication therewith comprising dividing a strip of metal stock on opposite sides of a longitudinal dividing line into an inner section on each side adjoining the center line and an outer section on each side adjoining the respective inner section, impressing into one face of one of said sections on each side of the dividing line complementary impressions of opposite sides of said cylinder plug recess, impressing into corresponding faces of the other of said sections on each side of the dividing line a plurality of parallel inwardly open and outwardly closed pin tubular depressions, spacing said depressions laterally with respect to each other, making the depressions on opposite sides complementary to each other and extending transversely of the axes of said first identified impressions, folding said opposite sides along the dividing line thereby to form the cylinder plug recess and the out wardly closed pin tubular bores and fastening said opposite sides together.

2. A method of forming a cylinder lock housing having a cylinder plug recess and pin tumbler bores in communication therewith comprising dividing a strip of metal stock on opposite sides of a longitudinal dividing line into an inner section on each side adjoining the dividing line and an outer section on each side adjoining the respective inner section, impressing on one face of said inner sections complementary impressions of opposite sides of said cylinder plug recess, impressing into corresponding faces of said outer sections a plurality of parallel spaced depressions of said pin tumbler bores with open inner ends communicating with the impressions extending transversely to the axes of said recesses and making closed outer ends for said depressions, making the depressions on opposite sides complementary to each other, folding said inner sections along the dividing line thereby to form the cylinder plug recess, and fastening said opposite sections in face to face engagement with opposite depressions of said pin tumbler bores facing each other whereby to complete the formation of said pin tumbler bores in outwardly closed and inwardly open form.

3. A method of forming a cylinder lock housing having a cylinder plug recess and pin tumbler bores in communication therewith by use of dies and a cylindrical mandrel comprising dividing a strip of metal stock of substantially uniform thickness on opposite sides of a longitudinal dividing line into an inner section on each side adjoining the dividing line and an outer section on each side adjoining the respective inner sections, impressing on one face of said inner sections complementary impressions of opposite sides of said cylinder plug recess, impressing into corresponding faces of said outer sections a plurality of pa .llel spaced semi-cylindrical depressions of said pin tumbler bores with open inner ends in communication with said respective impressions and with closed outer ends extending transversely to the axes of said depressions, making the semi-cylindrical depressions on opposite sides with closed outer ends complementary to each other and with edges of sides and outer ends of the depressions in the same plane, providing fiat areas outwardly of said closed outer ends on a plane with the edges thereof and providing fasteners on said areas, folding said inner sections along the dividing line over said cylindrical mandrel thereby to form the cylinder plug recess, and securing the edges of said depressions againstrnovemcnt with respect to each other by fastening said outer sections at end edges at locations 6 removed outwardly from said closed outer ends and at side edges thereof in face to face engagement with opposite semi-cylindrical depressions of said pin tumbler bores facing each other whereby to complete the formation of said pin tumbler bores in outwardly closed and inwardly open form.

4. A method of forming a cylinder lock housing having a cylinder plug recess and pin tumbler bores com prising preparing two pieces of metal of substantially uniform size and thickness, dividing each piece into a first section and a second section, impressing into corresponding faces of said first sections complementary recesses corresponding to partial portions of said cylinder plug recess, impressing into corresponding faces of said second sections transversely extending spaced parallel depressions in precisely located positions relative to the recess in the respective first section, making said depressions in the opp site second sections respectively complementary to each other, providing tabs at outer ends respectively of said first sections and said second sections, and providing in opposite sections receiving means for said tabs in positions wherein the tabs when received therein will be secure against shifting laterally, placing said faces of the two pieces in face to face engagement and folding said tabs into anchoring relationship with said pieces whereby said pieces are fastened together with recesses forming the plug recess and the complementary depressions form pin tumbler bores in precisely located relationship with said plug recess.

5. A method of forming a cylinder lock housing having a cylinder plug recess and pin tumbler bores comprising preparing two pieces of metal of substantially uniform size and thickness, dividing each piece into an inner section and an outer section, impressing into corresponding faces of said inner sections semi-cylindrical complementary recesses corresponding to half portions of said cylinder plug recess, impressing into corresponding faces of said outer scctions transversely extending spaced parallel semi-cylindrical depressions, said depressions in the opposite outer sections being made respectively complementary to each other, forming tabs at edges of one of said pieces and forming atcorresponding edges of the other of said pieces opening in alignment with selected tabs, placing said faces of the two pieces in face to face engagement and placing said tabs in the corresponding openings whereby to align the recess and the depressions and said pieces at outer and end edges respectively of the outer sections and at outer edges of the inner sections thereof whereby the bending said tabs of one piece over the edge of the opposite piece whereby to anchor semi-cylindrical complementary recesses form the plug recess and the semi-cylindrical depressions form the pin tumbler bores communicating with said plug recess.

References Cited in the file of this patent UNITED STATES PATENTS Booth July '31, 1956 

